Article – Added Value of Process Modelling in Development of Automotive Die Casting Parts

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Presented at the Japan Die Casting Congress, Yokohama, November 2018

Added Value of Process Modelling in Development of Automotive Die Casting Parts

Andre Le-Nezet1, Nicolas De Reviere¹, Loic Calba², Badarinath Kalkunte²
¹Groupe Renault, France, ²Calcom ESI SA, Switzerland,

Abstract
Porosity in high performance castings can reduce mechanical properties and consequently degrade both component life and durability. Automotive Market increasingly requests High Performance Castings with high structural integrity and good mechanical properties. These requirements are typically obtained with Gravity and Low Pressure Die Castings. High Pressure Die Castings, due to the process itself is not completely suitable to deliver such increasing requirements. However, because of the possibility of mass production with reduced shot times and hence costs, several
innovations and technologies have kept evolving around this process, making it a competitive and lucrative process for industries to consider.
Process Modelling provides a wide scope to test several of these technological advancements virtually and be an integral part in the development of the die casting parts. This would then enable the casting engineers to be able to both predict defects in advance and take actions to improve the process/design.

Keywords : Die Casting, HPDC, part design, die design, casting development loop, digital tuning, die cycling, simulation, Porosity, Workflow, Macros, Automatization, Renault, ESI

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